Method of forming assembled package with first ridge of first tray forming part of outer surface of assembled package

Abstract

The method includes forming a first tray with a first top surface, the first tray including first sidewalls that extend vertically downward from the first top surface, the first tray defining a first ridge extending horizontally away from the first sidewalls, and configuring an outer container to selectively contain the first tray when the outer container is in a closed position, a first outer surface of the first ridge forming part of an overall outer surface of the assembled package when the outer container is in a closed position.

What is claimed is: 
     
         1 . A method of forming an assembled package, comprising:
 forming a first tray with a first top surface, the first tray including first sidewalls that extend vertically downward from the first top surface, the first tray defining a first ridge extending horizontally away from the first sidewalls; and   configuring an outer container to selectively contain the first tray when the outer container is in a closed position, a first outer surface of the first ridge forming part of an overall outer surface of the assembled package when the outer container is in a closed position.   
     
     
         2 . The method of  claim 1 , wherein the configuring configures such that the outer container includes a first section and a second section. 
     
     
         3 . The method of  claim 2 , wherein the configuring configures such that the first section is identical to the second section. 
     
     
         4 . The method of  claim 2 , wherein the configuring configures such that the first ridge is held between a first peripheral edge of the first section and a second peripheral edge of the second section when the outer container is in the closed position. 
     
     
         5 . The method of  claim 1 , wherein the forming the first tray forms such that a first upper portion of the first sidewalls define at least one first indentation. 
     
     
         6 . The method of  claim 1 , wherein the forming the first tray forms such that a first upper portion of the first sidewalls define at least one first indentation that creates a first gap between an interior surface of second sidewalls of the outer container and the first sidewalls at the at least one first indentation. 
     
     
         7 . The method of  claim 6 , wherein the forming the first tray forms such that the at least one first indentation includes a first indentation and a second indentation, and the first sidewalls include a first sidewall and a second sidewall that oppose each other. 
     
     
         8 . The method of  claim 7 , wherein the forming the first tray forms such that upper portions of the first sidewall and the second sidewall respectively define the first indentation and the second indentation which oppose each other and run along a portion of a longitudinal length of the first sidewall and the second sidewall. 
     
     
         9 . The method of  claim 1 , wherein the forming the first tray forms such that a first upper portion of the first sidewalls define at least one first indentation, and a first portion of the first top surface partially defines the at least one first indentation, such that the first portion has a lower elevation than a remainder of the first top surface. 
     
     
         10 . The method of  claim 1 , wherein the forming the first tray forms such that the first tray defines an impression of a first consumer product. 
     
     
         11 . The method of  claim 10 , wherein the forming the first tray forms such that a lower surface of the first tray defines a reinforcing structure directly below at least a portion of the impression. 
     
     
         12 . The method of  claim 11 , wherein the forming the first tray forms such that the reinforcing structure includes ribs with a pair of longitudinal segments running parallel to each other and crosspiece segments spanning between the pair of longitudinal segments. 
     
     
         13 . The method of  claim 1 , wherein the forming the first tray forms such that the first sidewalls define at least one upper lug, the at least one upper lug extending from the first ridge towards the first top surface along a first outer surface of the first sidewalls. 
     
     
         14 . The method of  claim 1 , further comprising:
 forming a second tray with a second top surface, the second tray including second sidewalls that extend downward from the second top surface, the second tray defining a second ridge extending horizontally away from the second sidewalls.   
     
     
         15 . The method of  claim 14 , wherein the configuring configures such that the first tray and the second tray are selectively and individually removable from the outer container. 
     
     
         16 . The method of  claim 14 , wherein the forming the second tray forms such that the second ridge extends around an outer periphery of the second tray, an outer surface of the second ridge contacting an interior surface of the outer container when the outer container contains the first tray and the second tray. 
     
     
         17 . The method of  claim 14 , wherein the forming the second tray forms such that the second sidewalls, an upper surface of the second ridge, and third sidewalls of the outer container define a ravine, a distal end of the first sidewalls being fitted into the ravine when the outer container contains the first tray and the second tray. 
     
     
         18 . The method of  claim 17 , wherein the forming the second tray forms such that the ravine is defined along a periphery of the second tray. 
     
     
         19 . The method of  claim 14 , wherein
 the forming the first tray forms such that a first part of a lower surface of the first tray defines a reinforcing structure, a second part and a third part of the lower surface defines at least a portion of at least one first impression, and   at least some of the first part, the second part and the third part form three points of contact with at least one consumer item being held in the second tray to cause the first tray to be at least partially suspended apart from the second tray when the outer container contains the first tray and the second tray.   
     
     
         20 . The method of  claim 1 , further comprising:
 circumscribing a band around at least a portion of the outer container when the outer container is in the closed position, the band including at least one wide panel that is conformed to and in direct contact with at least one major surface of the outer container, the band defining at least one tear strip that runs across a width of a portion of the band, the at least one tear strip being aligned with and running in front of a portion of the first ridge.